ChapDrive AS – proprietary Technological advances in Hydraulic Drivetrains for Wind Turbines 9th Deep Sea Offshore Wind R&D Seminar DeepWind 2012 Knud Erik Thomsen, ChapDrive 2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 1
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ChapDrive AS – proprietary
Technological advances in Hydraulic Drivetrains for Wind Turbines
9th Deep Sea Offshore Wind R&D Seminar DeepWind 2012
Knud Erik Thomsen, ChapDrive
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 1
ChapDrive AS – proprietary
Company background ChapDrive compact and integrated variable hydraulic drivetrain Technological advantages Why are frequency converters needed in today’s wind turbines? How can ChapDrive avoid using frequency converters? Dynamic models and ChapDrive Control System Measurements and model verification
Measurements - Variable speed control Measurements - Dynamic load control Low Voltage Ride Through, LVRT, measurements
Conclusion ChapDrive technology verification history and future Question and answer
Contents
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 2
ChapDrive AS – proprietary
Developed by leading scientists and product developers in hydraulic systems
and turbine technology since 2004. The company was formally founded in
2006.
20 employees in Norway, Denmark, UK and China
Current funding secured in 2010 - EUR 10 mill from the investors:
NorthZone Ventures, Statoil Venture, Hafslund Venture, Viking Venture and Investinor
Company background
3
From left: Headquarter in Trondheim, subsiduary in Denmark, workshop in Trondheim and test site at Valsnes
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012
ChapDrive AS – proprietary
ChapDrive compact and integrated variable hydraulic drivetrain
Pump
Motor
Synchronous generator
Control System
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012
Perfection via
Simplicity
4
ChapDrive AS – proprietary
ChapDrive offers a unique alternative gearless solution
Robust light-weight variable hydraulic drivetrain with synchronous generator and fewer critical components
No mechanical gearbox - causing high maintenance costs on today’s wind turbines
No frequency converter - causing the highest failure rates and most down time on today’s wind turbines
No need for permanent magnets - high cost rare earth materials
No transformer
Technological advantages
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 5
ChapDrive AS – proprietary
Purpose of the frequency converter: Variable speed control
Optimises energy production
Dynamic load control Reduces power and torque fluctuations, extreme loads etc.
Grid control Stabilises the grid via reactive power control, low voltage ride through
control etc.
History: Up till 1990: No frequency converters 1990 till today: 25 – 30% of rated power frequency converters in
combination with double feed induction generators, DFIG Future turbines: Full scale frequency converters, 100 % of rated
power in combination with medium speed permanent magnet generators or direct drive permanent magnet generators
Why are frequency converters needed in today’s wind turbines?
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 6
ChapDrive AS – proprietary
How can ChapDrive avoid using frequency converters?
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 7
Gearbox Double fed
induction generator Frequency converter Transformer
Grid
10 kV
Grid
10 kV
Hydraulic transmission
Synchronous generator
ChapDrive AS – proprietary 2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 8
Gearbox Double fed
induction generator Frequency converter Transformer
Grid
10 kV
Grid
10 kV
Synchronous generator
Speed control
Speed control
Where is the speed control done?
Hydraulic transmission
ChapDrive AS – proprietary
Gearbox, Direct drive and ChapDrive
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 9
Grid
10 kV
Gearbox (Fixed, e.g. 1 : 100 @ 3 MW)
Double fed induction generator Frequency converter Transformer
Grid
10 kV
Frequency converter Transformer
Grid
10 kV
Direct drive generator (Fixed 1 : 1)
Conventional gearbox
Direct drive
ChapDrive
Hydraulic transmission (1 : variable)
Synchronous generator
ChapDrive AS – proprietary
Optimal rotor speed at all wind speeds
Transmission ratio: Variable 1:100 – 1:300 for a 3 MW wind turbine
Result: High energy yield from the wind Low loads on the turbine structure
and the turbine components
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 10
ChapDrive AS – proprietary
A complete new drivetrain concept requires new dynamic models and new control strategy
Dynamic models and ChapDrive Control System
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 11
ChapDrive AS – proprietary
Dynamic models of wind turbine Dynamic models of:
Blades & aerofoil
Rotor
Nacelle structure
Tower structure
Hydraulic Drive Train
ChapDrive Control system
Wind interface
Foundation interface
Grid interface
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 12
ChapDrive AS – proprietary
Dynamic models hydraulic drivetrain Dynamic models of: Blades & aerofoil
Rotor
Nacelle structure
Tower structure
Hydraulic Drive Train Hydraulic pump
Digital hydraulic motor Digital valve technology
Synchronous generator Grid and wind turbine park
Auxiliaries (Cooling, boost, etc.)
ChapDrive Control system Wind interface
Foundation interface
Grid interface
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 13
ChapDrive AS – proprietary
ChapDrive Control System Dynamic models of: Blades & aerofoil
Rotor
Nacelle structure
Tower structure
Hydraulic Drive Train
ChapDrive Control System Pitch control
Displacement control Digital valve control
Excitation control of generator
Turbine control (state, yaw, temperature, etc.)
Wind interface
Foundation interface
Grid interface
ChapDrive Control System
Low Speed Unit Pump
Pitch Control Excitation Control
Displacement Control
Synchronous Generator
High Speed Unit Motor
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 14
ChapDrive AS – proprietary
Model verification
Dynamic models
Model Verification
ChapDrive Control
Software
Wind turbine
ChapDrive Control System
1
2
3
4x 10
4
Tp [
Nm
]
System inputs
4
4.5
5
5.5
6x 10
-5
Dm
[m
3/r
ad]
30
35
40
45
50
p [
rpm
]
System outputs
50
100
150
200
pm
,in [
bar]
0 100 200 300 400 500 600 700 800 9000
50
100
150
Pg [
kW
]
(Measurement start time: 2011-12-07 11:24:00) t [s]
20
40
60
80
p [
rpm
]
System outputs
50
100
150
200
pm
,in [
bar]
0 100 200 300 400 500 600 700 800 9000
50
100
150
Pg [
kW
]
(Measurement start time: 2011-12-07 11:24:00) t [s]
Comparison
Model tuning
Simulation results
Measurements
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 15
ChapDrive AS – proprietary
Measurements - Variable speed control
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 16
10 minutes mean values are shown from the test wind turbine, ChapDrive 1, for a period of 5 month
Optimal rotor speed at all time ensuring maximum energy yield from the wind
Generator speed is always constant.
ChapDrive AS – proprietary
Method Combined and
optimised control of: Pitch Displacement
(transmission ratio) Excitation
Result Constant power above rated
wind speed Power and torque
fluctuations eliminated due to fast displacement control
Full control over reactive power
Measurements - Dynamic load control
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 17
ChapDrive AS – proprietary
Installed LVRT test equipment between grid and the test wind turbine, ChapDrive 1 Inductances Resistors Breakers Fast measurement equipment
6 x voltages 6 x currents Excitation voltage and current
Voltage dip range: 0 – 100 % of nominal voltage
The above equipment - together with the ChapDrive DataLog system, sampling approx. 250 other turbine variables - are creating a large information database for continuous optimisation of the combined control of: Pitch Displacement Excitation
Low Voltage Ride Through, LVRT, measurements on ChapDrive 1
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 18
Turbine stays on grid during a LVRT situation
ChapDrive AS – proprietary
ChapDrive has demonstrated that the combination of a variable hydraulic drivetrain and new optimised control strategy can eliminate the need for: Mechanical gearbox Frequency converter (*) Permanent magnets Transformer All contributing to reduced Cost of Energy, CoE (*) The combination of a variable hydraulic transmission, a synchronous generator and the ChapDrive Control System has taken over the tasks of the full scale frequency converter seen in nearly all new wind turbine developments. These tasks are: Variable speed control
Optimises energy production
Dynamic load control Reduces power and torque fluctuations, extreme loads etc.
Grid control Stabilises the grid via reactive power control, low voltage ride through control etc.
Conclusion
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 19
ChapDrive AS – proprietary
Hydraulic transmissions are robust and will reduce top weight for wind turbines
High efficiency hydraulic technology enables competitive efficiency
Development is driven by the industry for mobile hydraulic systems
ChapDrive will install such technology in the 225 kW test turbine in H1 2012
ChapDrive’s hydraulic solution is verified in fully operational 225 and 900 kW test turbines
ChapDrive is now developing a 3.x MW integrated drivetrain based on high efficiency hydraulic technology
ChapDrive technology verification history and future
20
3+ MW integrated drive train
5+ MW conceptual design
225 kW test turbine
50 kW test bench
900 kW test turbine
300 kW test bench
Technology verification and development well progressed since company inception
2005 2007 2009 2011 – 2013
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012
ChapDrive AS – proprietary
Question and answer
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 21
ChapDrive AS – proprietary
Thank you for your attention!
2012-01-19 9th Deep Sea Offshore Wind R&D Seminar – DeepWind 2012 22
Professor Brochs gt 2 Trondheim 7030 Norway www.chapdrive.com
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